1. PEMBUKAAN PAINPOINT DRIVEN

Adakah anda menguruskan operasi pengeluaran agregat berskala midtolarge dan menghadapi kesesakan berterusan yang menghakis keuntungan? Untuk pengurus loji dan kontraktor kejuruteraan, loji penghancur batu 250300tph mewakili peringkat pengeluaran yang kritikal, namun cabaran operasi biasa boleh menjejaskan pulangan pelaburannya dengan ketara.

Inconsistent Throughput & Downtime: Pemberhentian yang tidak dirancang kerana penyuapan tersumbat, lebihan penghancur, atau salah jajaran penghantar boleh menelan belanja ribuan sejam dalam kehilangan pengeluaran dan buruh terbiar.
Beroperasi Tinggi & Kos penyelenggaraan: Are you constantly budgeting for premature wear part replacement, excessive energy consumption from inefficient crushing chambers, or unscheduled maintenance labor?
Kebolehubahan Kualiti Produk: Fluctuations in final product gradation and excessive flakiness can lead to rejected loads, penalti kontrak, and damage to your market reputation.
Skalabiliti & Had Fleksibiliti: Can your current setup efficiently handle variations in feed material hardness (daripada batu kapur kepada granit) or quickly adapt to changes in required product specs without major reconfiguration?

Persoalan utama ialah: bagaimana anda mencapai kebolehpercayaan, costperton production within the 250300tph range while maintaining product integrity and controlling operational expenses?

2. GAMBARAN KESELURUHAN PRODUK

Penyelesaian ini adalah pegun 250300 tan sejam (tph) hard rock crushing and screening plant designed for highvolume aggregate production. Engineered as a complete circuit, it transforms large feed material into precisely graded commercial aggregates.

Aliran Kerja Operasi:
1. Pengurangan utama: Large quarryrun rock (up to 750mm) is consistently fed into a robust primary jaw crusher for initial size reduction.
2. Sekunder & Penghancuran tertiari: Keluaran dihantar ke penghancur kon sekunder untuk pengurangan selanjutnya, with optional tertiary crushers or impactors for shaping and fine crushing.
3. Saringan Bahan: Multipledeck vibrating screens accurately separate crushed material into specified size fractions (mis., 05mm, 510mm, 1020mm).
4. Stok & Recirculation: Bahan onspec dihantar ke stok simpanan yang ditetapkan. Bahan bersaiz besar secara automatik diedarkan semula ke dalam litar untuk rerushing, ensuring efficiency.

Skop Permohonan: Ideal untuk menghasilkan agregat untuk asas jalan, asfalt konkrit, Ballast Keretapi, and construction projects requiring highvolume, specificationgrade material.

Batasan: This plant configuration is designed as a stationary or semistationary installation. It requires proper foundational support and is intended for mediumtohard abrasives (kekuatan mampatan <350MPa). For fully mobile applications or processing softer materials like clayrich rock without prescalping, alternative configurations may be recommended.

3. CIRI TERAS

Penghancur Rahang Utama Kapasiti Tinggi | Asas Teknikal: Kinematik yang dioptimumkan & heavyduty roller bearing design | Faedah Operasi: Handles peak feed loads with reduced stress cycles, minimizing risk of stall or fatigue failure | Kesan ROI: Data medan menunjukkan sehingga 15% lower downtime risk versus standard designs, melindungi aliran pendapatan.

Automasi Ruang Penghancur Pintar | Asas Teknikal: Hydropneumatic tramp release and clearing system with PLCcontrolled setting adjustment | Faedah Operasi: Automatically handles uncrushables and allows remote adjustment of crusher settings for product size changes | Kesan ROI: Reduces unplanned interventions by up to 80% and enables faster product changeovers, meningkatkan penggunaan tumbuhan.

MultiStage Precision Screening System | Asas Teknikal: HighGforce linear motion screens with modular tensioned screen decks | Faedah Operasi: Delivers sharp separations even under high feed rates and damp conditions; decks are replaceable individually | Kesan ROI: Improves final product yield accuracy by an estimated 812%, mengurangkan sisa dan memaksimumkan tonase yang boleh dijual.

Kawalan Proses Berpusat & Pemantauan | Asas Teknikal: SCADAbased control panel with motor current monitoring, chute blockage detection, and wear part tracking | Faedah Operasi: Your operators manage the entire flow from a single station with realtime alerts on performance deviations | Kesan ROI: Enables predictive maintenance scheduling and reduces troubleshooting time by approximately 30%, optimizing labor efficiency.

HeavyDuty Conveyor System with Impact Zones | Asas Teknikal: Pembinaan rangka saluran dengan pemalas hentaman pada titik pemuatan dan tali pinggang tahan lelasan | Faedah Operasi: Withstands continuous hightonnage operation with minimal belt stretch or damage at transfer points | Kesan ROI: Extends belt service life by an average of 25%, directly lowering consumable costs per ton produced.

Modular Electrical System Design | Asas Teknikal: IPrated motor control centers (MCC) with standardized connections and clear cable routing | Faedah Operasi: Simplifies installation onsite and allows for easier future expansion or component replacement during service | Kesan ROI: Can reduce initial installation electrical labor costs by approximately 15% compared to nonmodular systems.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri untuk Loji 250300tph | Penyelesaian Tumbuhan Ini | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Adanya / Masa aktif | ~8588% (termasuk penyelenggaraan yang dirancang) |>92% Target Availability| +47% Lebih Masa Pengeluaran |
| Kecekapan tenaga (kWj/tan)| Berbeza secara meluas; garis dasar ditetapkan pada 100%| Industry testing demonstrates ~95% of baseline consumption| ~5% Reduction in Power Cost |
| Kos Bahagian Pakai setiap Tan| Cost index = 100% (untuk granit yang kasar)| Cost index = ~87% via optimized alloys & chamber designs| ~13% Lower Consumable Cost |
| Persediaan Purata / Masa Pentauliahan| 810 minggu (foundation to first crush)| Sasaran: 68 Weeks with modular design| Hingga 25% Penggunaan Lebih Cepat |
| Kecekapan Jejak (Tons/hr/m²)| Garis dasar = 100%| Compact flow design achieves ~115% of baseline| ~15% Better Space Utilization |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti Direka: 250 300 Ton metrik sejam (tph), bergantung pada kekerasan bahan suapan (<350 Kekuatan mampatan MPa) dan penggredan produk yang diperlukan.
Keperluan Kuasa Utama: Lebih kurang. 550 650 kW jumlah beban bersambung. Typical supply: 400V/50Hz or customized voltage/frequency.
Spesifikasi Bahan Utama:
Plat Rahang Penghancur Utama / Pelapik Kon: Aloi keluli mangan (Mn18Cr2/Mn22Cr2).
Dek Skrin: Highcarbon steel wire mesh or polyurethane panels.
Struktur Kerangka Utama: Fabricated from S355JR grade steel.
Belting Penghantar: EP630/3 minimum ply rating with abrasionresistant top cover.
Approximate Physical Dimensions (L x W x H): Berbeza mengikut susun atur; typical compact arrangement fits within ~65m L x 28m W x 15m H envelope.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C. Sistem penindasan habuk disertakan; kandang tersedia untuk operasi cuaca ekstrem.

6. SENARIO APLIKASI

Highway Construction Project Supply

Challenge A contractor needed a guaranteed supply of over 500,000 tons of multiple aggregate specifications within an18month window from a variable hardness granite quarry.
Solution Implementation of this configured plant solution featuring primary jaw crushing followed by two secondary cone crushers feeding a tripledeck screening system.
Results The plant achieved an average sustained output of280 tph at the required specifications.Availability exceeded91%, enabling the project supply contract to be fulfilled4 weeks ahead of schedule.

Commercial Aggregate Producer Expansion

Challenge An established producer sought to expand into the premium concrete aggregate market but their existing plant produced excessive flaky particles.
Solution Integration of this solution configured with a shaping tertiary impact crusher stage after primary/secondary crushing,and highprecision screens.
Results Product cubeicity improved significantly,fines production was better controlled,and the producer captured new contracts at apremium price point.Plant flexibility allowed quick switching between asphaltand concrete spec materials.

7. PERTIMBANGAN KOMERSIL

Pendekatan kami memberikan kejelasan dalam perancangan pelaburan:

Peringkat Harga: Kami menawarkan tiga konfigurasi teras:
Peringkat A (Essential Performance) – Core crushing/screening circuit meeting250 tph spec on standard materials.Lower initial capex focus.
Peringkat B (Optimized Production) – Enhanced features including automation,intelligent controls,and superior wear components.Recommended configuration formost hard rock applications up to300 tph.Best balanceof capexand lifetimeoperating cost(LTOC).
Peringkat C (Maximum Uptime) – Includes full environmental enclosures,penimbang tali pinggang,predictive monitoring sensors,and premium component packages.Designedfor operations wheremaximizing runtimeis critical despite higher initial investment

Ciri Pilihan: Dust extraction systems,washing attachments,penimbang tali pinggang,pemisah magnetik,customized walkways/service platforms

Pakej Perkhidmatan: Pilih daripada rancangan pemeriksaan tahunan,wear part kitswith guaranteed pricing,inventory management programs,and remote diagnostics support

Financing Options Available through partner institutions including equipment leasing,tailored loan structures,and renttoown programs subjectto credit approval

Soalan Lazim

Q1 Is this plant compatible with our existing primary feeding systemand stockpile conveyors?
A Yes.The plantis designedwith standardized interface heightsand conveyor speeds.Engineering specifications are provided upfrontto ensure compatibilitywith your site's specific feed hopperand downstreaminfrastructure

Q2 Whatisthe expected lead timefrom orderto commissioning?
A For standard configurationslead times typically range between20and28 weeksdependingon complexityFinal site commissioningrequiresapproximately2weekswith oursupervision subjectto site readiness

Q3 How does thisplant manage fluctuationsin feedmaterial hardness?
A Thecrushing chambersare designedfor awide reductionratioandthe control systemmonitors motorloadautomatically adjustingfeedratesvia theprefeeder tomaintain optimal throughputand protectthecrushersfrom overload

Q4 Whatisthe typical manpowerrequirementto operatethisplant?
A The centralizedcontrolsystemallows forefficientoperationbyonecontrolroomoperatorper shiftOneadditional groundpatrolpersonnelisrecommendedfor visual inspectionsTotal directlaboris typicallytwo personsper shift

Q5 Arewearparts readilyavailableand whatarethe expectedconsumptioncosts?
A We maintainaglobal inventoryofcriticalwearpartsConsumptioncostsarequotedonapertontreatedbasisbasedonyour specificfeedmaterialanalysiswith mosthardrockapplicationsfallingwithinapredictablerangeGuaranteed pricingprogramsareavailable

Q6 Do youprovide trainingfor ourmaintenance crew?
A YesComprehensive trainingfor bothoperatorsandmaintenance techniciansisprovidedduringcommissioningThisincludeshandson instructionaswellasdetailedmanualsandschematicaccess

Q7 Canthisplantbedesignedfor futurecapacityexpansionbeyond300tph?
A Themodulardesignofthestructural supports electricalinfrastructureandconveyor systemsfacilitatesfutureexpansionEngineeringconsultationisrecommendedduringtheinitialplantlayoutphaseto planforsuch scalability